Protective mask, material and kit

ABSTRACT

Disclosed is a personal protection kit comprising a mask sized to cover a wearer&#39;s nose and mouth and having a perimeter size and shape and a tacky cured silicone material having a size and shape to match the mask perimeter size and shape. Also disclosed is a self-adhesive mask including a tacky cured silicone material. A tacky cured silicone material having the shape of a face mask perimeter is disclosed as well as a tape made of the tacky cured silicone material. Also described herein is a protective face mask including a flexible mask body sized to fit over a nose and mouth of a wearer and having central opening and a removable barrier covering the central opening.

BACKGROUND

Wearing protective face masks has become standard procedure in many industries including health care and manufacturing. The use of a face mask can be important to protect the wearer from environmental hazards which can include body fluids, particulates, gases and the like. Face masks also find use in patient care as part of respiratory treatment and sleep treatment. Additionally, face masks are found in recreational activities such as snorkeling and scuba diving.

BRIEF SUMMARY

Described herein is a self-adhesive face mask including a mask body sized to fit over a nose and mouth of a wearer and having a perimeter and a tacky cured silicone material located on the perimeter of the mask body wherein the tacky cured silicone material removably adheres to human skin without residue.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the tacky cured silicone material may be continuous around the perimeter of the mask body.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the tacky cured silicone material may be discontinuous around the perimeter of the mask body.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the mask body may be cup shaped.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the mask body may be non-molded.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the mask body may be fluid permeable.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the mask body may not be fluid permeable.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the tacky cured silicone material may have a thickness of 0.1 to 4 millimeters (mm).

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the tacky cured silicone material may have a width of 1 to 25 mm.

Also disclosed is an article including a tacky cured silicone material having the shape of a face mask perimeter.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the tacky cured silicone material has a thickness of 0.1 to 4 mm.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the tacky cured silicone material has a width of 1 to 25 mm.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the face mask perimeter is sized to extend past a wearer's nose and mouth.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the face mask perimeter is sized to extend past a wearer's eyes, nose and mouth.

Also disclosed is a personal protection kit including a mask sized to cover a wearer's nose and mouth and having a perimeter size and shape and a tacky cured silicone material having a size and shape to adhere to the mask perimeter size and to a wearer's face.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the mask may be cup shaped.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the mask may be non-molded.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the mask may be fluid permeable.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the mask may not be fluid permeable.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the tacky cured silicone material may have a thickness of 0.1 to 4 mm.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the tacky cured silicone material may have a width of 1 to 25 mm.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the tacky cured silicone material is continuous with the mask perimeter.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the tacky cured silicone material is discontinuous with the mask perimeter.

Also disclosed is a tape including a tacky cured silicone material wherein the tape has first side and a second side opposite to the first side and the first side and second side are tacky.

Also disclosed is a protective face mask including a flexible mask body sized to fit over a nose and mouth of a wearer and having central opening and a removable barrier covering the central opening.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, at least a portion of the flexible mask body is formed from a non-tacky cured silicone.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the central opening has a perimeter smaller than the perimeter of the removable barrier.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the central opening is surrounded by a tacky material. The tacky material may be disposed on the flexible mask body or may be integral to the flexible mask body. The tacky material may be a cured tacky silicone material that retains tackiness after washing and can be reused.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the central opening is surrounded by a material different from the remainder of the flexible mask body.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the removable barrier is attached to the mask body by an interlocking attachment means.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the perimeter surrounding the central opening has a slot and the removable barrier is sized to fit the slot.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the removable barrier has a perimeter larger than the perimeter of the central opening.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the removable barrier includes a filter material optionally in combination with other material(s).

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the flexible mask body has a side facing a wearer and a side opposite of the wearer and the removable barrier is located on the side facing the wearer.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the flexible mask body has a side facing a wearer and a side opposite of the wearer and the removable barrier is located on the side opposite of the wearer.

In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the flexible mask body may have a thickness of 0.1 to 4 millimeters (mm).

Also disclosed is a personal protection kit including a protective face mask as described above and at least one additional removable barrier.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the present invention will be more fully understood from the following detailed description of illustrative embodiments, taken in conjunction with the accompanying drawings in which like elements are numbered alike:

FIGS. 1A, 1B and 1C show front and rear views of a non-molded mask;

FIG. 2 shows the rear of a cup shaped mask;

FIG. 3 shows a tacky cured silicone material having a mask perimeter size and shape;

FIG. 4 shows a silicone component of a multi part mask;

FIG. 5 is an exploded view of a multi part mask;

FIG. 6 shows a flexible mask body;

FIG. 7 shows a flexible mask body with a covered central opening;

FIG. 8 shows a flexible mask body with a central opening surrounded by tacky material;

FIG. 9 is a cross section through FIG. 7; and

FIG. 10 shows a removable barrier material with tacky material.

DETAILED DESCRIPTION OF THE INVENTION

Disclosed herein is a self-adhesive face mask that has a tacky cured silicone material located on the perimeter of the face mask to allow the mask to removably adhere to a face without leaving a residue that needs to be cleaned. The mask can be reused multiple times (i.e. multiple re-adhesions) and can withstand heat, rain, wind, cold and complete water submersion without losing adhesion. Alternatively a tacky cured silicone material may be used with an existing face mask. The tacky cured silicone material used with an existing face mask may have the shape of the mask perimeter or may be discontinuous pieces of tape that can be adhered to the mask and the mask wearer. It is also contemplated that a mask and a tacky cured silicone material may be combined for a personal protection kit.

The self-adhesive face mask and the combination of a mask and a tacky cured silicone material removes the need for ties or elastic bands to affix the mask to the face of the wearer. Ties or elastic bands may still be employed if desired. The tacky cured silicone material may reduce or eliminate gaps between the mask and the wearer which increases the effectiveness of the mask.

FIG. 1A shows a front view of a non-molded mask 10 having a perimeter 20 and an optional flexible portion 30 to conform a portion of the mask to the bridge of the wearer's nose. FIG. 1B is a rear view of a non-molded mask 10 having a perimeter 20 and a continuous tacky cured silicone material 40 on the perimeter. FIG. 1C is a rear view of a non-molded mask 10 having a perimeter 20 and a discontinuous tacky cured silicone material 40 on the perimeter. The tacky cured silicone material is shown with a checked pattern in FIGS. 1B and 1C for clarity.

FIG. 2 shows a rear view of a cup shaped mask 50 having a perimeter 20 and an optional flexible portion 30 to conform a portion of the mask to the bridge of the wearer's nose. Tacky cured silicone material 40 is located on the perimeter 20.

FIG. 3 shows a continuous tacky cured silicone material 80 in the shape of a face mask perimeter. The material has a thickness 60 and a width 70.

The tacky cured silicone material has high tack properties such that the outer surface is tacky (sticky) to the touch. “Tacky”, as used herein, refers to a material which is sticky to the touch and can adhere up to 1 gram of weight per square centimeter of tacky cured silicone to a vertical section of human skin for greater than or equal to 15 minutes. It should be appreciated that the tacky cured silicone material leaves little and/or no film on the skin after removal.

The tacky cured silicone material is a hypoallergenic skin safe material. The tacky cured silicone material may be permanently affixed to the mask or may be removable. When the tack cured silicone material is removable the material may be was, if needed, and reused. The tacky cured silicone material may be any silicone material suitable to the desired end purpose, such as, but not limited to, platinum cured silicone, tin cured silicone, RTV silicone and/or silicone gum. These materials are commercially available. Suitable materials include High Tack Silicone Gel A-4717 available from Factor II. Additionally, other commercial silicone materials such as Dragon Skin® available from Smooth-On can be modified by adding a silicone fluid such as Slacker® Tactile Mutilator available from Smooth-On and Si-Thinner available from Silicones Inc. The silicone fluid may be a low viscosity (<100 centistokes) non-reactive silicone fluid. The amount of the silicone fluid combined with the commercial silicone material will depend somewhat upon the molecular weight and characteristics of the commercial silicone material. A material which has a softer and more gel like feel will need less silicone fluid than a more rigid material to obtain the desired tackiness for adhesion to human skin. In an exemplary embodiment 15 weight percent of Dragon Skin® is mixed with 85 weight percent of Slacker® Tactile Mutilator, based on the combined weight of Dragon Skin® and Slacker® Tactile Mutilator, to form the tacky cured silicone material.

The tacky cured silicone material may have a thickness of 0.1 to 4 mm, or, 0.5 to 3 mm, or 0.5 to 2 mm. The tacky cured silicone material may have a width of 1 to 25 mm, or, 1 to 20 mm, or, 1 to 15 mm.

The tacky cured silicone material may be made using a two part, clear to translucent, pourable silicone system that cures at room temperature to form a tacky material. Polymerization may occur without formation of heat. Polymerization may occur at room temperature without the application of heat. It is contemplated that the tacky cured silicone material may be tin cured silicone, RTV silicone and/or silicone gum and, in some embodiments, heat may be used to accelerate the curing process. It should be appreciated that in another embodiment, the tacky cured silicone material is not limited to a two part clear to translucent, pourable silicone system that cures at room temperature to form a tacky material and may be any tacky cured silicone material suitable to the desired end purpose. Thus, the system may have more or less than two parts.

For example, for some silicone materials, two parts are mixed together (A &B—where one is a catalyst and the other is the base). Sometimes they are both liquids. Sometimes only one part is a liquid (for example, the catalyst) and the other is more like molasses consistency (for example, the base). If A&B are liquids, the silicone material may be “poured” or spread onto a surface of a mask or into a mold before or after curing. If A&B are thicker, like molasses, the silicone material may be painted or pressed onto the mask or mold. It is also contemplated that the silicone material (before or after curing) may be formed into a sheet and then cut or stamped into the desired shape.

The silicone material may be formed or applied using an appropriate method. A release layer may be applied to one or more surfaces of the material to keep unwanted particulates from adhering to the surface. In embodiments where the tacky cured silicone material is integral to the self-adhesive mask the material may be formed first and then attached to the mask or the material may be formed directly on the mask. A non-removable adhesive may be desired to permanently adhere the tacky cured silicone material to the self-adhesive mask. The barrier portion of the mask (the barrier material) may be a single layer material.

In some embodiments the mask can include a barrier material and a first silicone component, a second silicone component, or both. The first silicone component has a non-tacky side disposed opposite to a tacky side. The first silicone component may include a non-tacky cured silicone material which forms a layer and provides the non-tacky side. The non-tacky cured silicone material is disposed adjacent to a layer of a tacky cured silicone material which provides the tacky side of the first silicone component.

The second silicone component has a first tacky side disposed opposite to a second tacky side. The second silicone component is formed from a tacky cured silicone material. The barrier material may be disposed between the tacky side of the first silicone component and the first tacky side of the second silicone component. The first silicone component and the second silicone component have an open central portion. The barrier material fills or covers the open central portion. The barrier material may meet or exceed N95 standards. The barrier material may be a single layer of material. The second tacky side of the second silicone component may be adhered to the face of the wearer. The first and/or second silicone component may have elastic loops or other attachment means (e.g., taped, stapled, sewn, or adhered) to or integral to the material as a supplemental means for securing the mask to the wearer. The barrier portion may have elastic loops or other attachment means attached (e.g., taped, stapled, sewn, or adhered) to or integral to the barrier portion.) The barrier portion may be removable from the first and/or second silicone component, and/or disposable. The silicone components can be washed, disinfected, and reused. The silicone components can be autoclaved.

It is further contemplated that the barrier material may be used in combination with the first silicone component without the second silicone component and the tacky side of the first silicone component adheres the mask to the face of the wearer. It is also contemplated that the barrier material may be used in combination with the second silicone component without the first silicone component. The barrier material has a perimeter that is less than or equal to the perimeter of the first silicone component, the perimeter of the second silicone component or the perimeters of both the first and the second silicone components. The barrier material has a perimeter which is greater than the perimeter of the open central portion of the first silicone component, greater than the perimeter of the open central portion of the second silicone component or greater than the perimeters of the open central portions of both the first and the second silicone components.

FIG. 4 shows a first silicone component 150 having a non-tacky side 100 and an open central portion 90. FIG. 5 is an exploded view of a mask showing the first silicone component 150 having a non-tacky side 100, open central portion 90, and optional supplemental attachment means 130. Barrier material 120 is located between the tacky side of the first silicone component (not shown) and the first tacky side 135 of the second silicone component 140. Barrier material 120 is sized to cover or fill the open central sections of the two silicone materials and contact with the first silicone material and/or the second silicone material sufficiently to hold the barrier material in place.

The mask components may be provided as a kit and assembled by the user. The tacky sides of the silicone materials may be in contact with a release layer which may also be reusable. The mask may be assembled by peeling the release layer from the tacky side of the first silicone material, contacting a portion the barrier material with at least a portion of the tacky side of the first silicone material, and contacting at least a portion of the first tacky side of the second silicone material with the tacky side of the first silicone material. A portion of the first tacky side of the second silicone material may be in contact with the barrier material. It is also possible for the mask components to be at least partially pre-assembled. For example, the barrier material may be provided with the first silicone component pre-adhered and/or the second pre-adhered with the appropriate release materials on the opposite side as needed.

The mask or mask body may be any type of protective mask. The mask or mask body may be non-molded or molded. Exemplary mask types include surgical masks, respirator masks, oxygen mask, CPAP masks, snorkel masks, particulate masks, scuba masks and the like.

It is further contemplated that the tacky cured silicone material tape may have additional uses beyond adhering to a mask. The tacky cured silicone material tape may be employed as a reusable adhesive in any format where tape is employed such as costumes, formal wear, home decorating, journaling, crafts, and the like. The tacky cured silicone material tape may also take the form of dots, squares or other discrete shapes.

Also disclosed herein is a protective face mask that has a flexible mask body sized to fit over a wearer's nose and mouth. The flexible mask body has a central opening and a removable barrier covering the central opening. The removable barrier can easily be removed and replaced with a fresh removable barrier. It is also contemplated that a protective face mask and more than one removable barriers can be combined for a personal protection kit.

The flexible mask body offers greater comfort to the wearer and less leakage around the removable barrier due to a closer fit to the wearer's face. Additionally, the easy replacement of the removable barrier facilitates replacement of the removable barrier when needed and simplifies manufacturing.

The flexible mask body is formed, at least in part, from a non-tacky cured silicone or other flexible material. The flexible material may be capable of conforming to a wearer's face with gaps of less than or equal to 5, 4, 3, or 2 millimeters when the mask wearer attachment means are located in the intended position. Exemplary mask wearer attachment means include, but are not limited to, loops, ties and straps. These attachment means may be integral to the mask body or may be attached thereto. The mask wearer may secure the mask to the wearer's face using the wearer's ears as anchoring points (i.e., using elastic loops) or may use the wearer's head as the anchoring point (i.e., using straps or ties).

The flexible mask body may be formed of more than one material. In some embodiments the area surrounding the central opening on one side of the mask may include a tacky material. The removable barrier can then adhere to the tacky material. Exemplary tacky materials include a tacky cured silicone material. The tacky cured silicone material can be washed or rinsed and regains tackiness when dry.

In some embodiments the area surrounding the central opening is formed from a material that facilitates adhesion of a tacky material located on the removable barrier to the mask body.

It is further contemplated that the removable barrier may be removably attached to the mask body using a non-adhesive means such as interlocking attachment means. For example, interlocking attachment means such as snaps or hook and loop attachments may be used. It is further contemplated that the mask body may include a slot and the removable barrier sized to fit into the slot. When the removable barrier is attached to the mask body using non-adhesive means the removable barrier may be located on the mask body on a side opposite to the wearer.

The mask body may further include a conformable portion which is, in some embodiment, located adjacent to the bridge of the wearer's nose. The conformable portion is less flexible than the remainder of the mask body and can be formed into a desired configuration which is retained. For example, the conformable portion may be shaped to fit the mask across the wearer's nose.

The mask body may have a thickness of 0.1 to 4 mm, or, 0.5 to 3 mm, or 0.5 to 2 mm.

The mask body may be formed using an appropriate method. A release layer may be applied to one or more tacky surfaces, when present, of the mask body and/or removable barrier to keep unwanted particulates from adhering to the surface.

The removable barrier covers the open central portion. The removable barrier may include a material that meets or exceeds N95 standards. N95 standards refers to the ability to exclude 95% of particulates having a size greater than or equal to 0.3 micrometers. The removable barrier may be a single layer material. The removable barrier has a perimeter larger than the perimeter of the central opening. The removable barrier may have a tacky material located on the perimeter of the removable barrier to attach the removable barrier to the mask body and cover the central opening. The tacky material on the removable barrier is a removable adhesive—forming a stronger bond with the removable barrier than the mask body. The bond with the mask body has a peel strength less than a hand applied force but greater than the force required to retain the removable barrier in place on the mask body. Stated another way the bond is sufficient to hold the removable barrier in place but weak enough to be removed by the wearer.

The mask components may be provided as a kit and assembled by the user.

Turning now to the Figures, FIG. 6 shows a flexible mask body 200 having a central opening 90 and integral loops 210 for anchoring the mask to the wearer's ears. FIG. 7 shows a flexible mask body 200 having a central opening (not shown) covered by a removable barrier 120. FIG. 8 shows flexible mask body 200 having a central opening 90 surrounded by a tacky material 40. FIG. 9 shows a cross section through FIG. 7 showing the removable barrier 120 in a slot 220 formed in the mask body 200. It is further contemplated that instead of slot 220 the mask body may have a channel sized to allow the removable barrier to drop into place. The removable barrier may include a gasket which fits into the channel. FIG. 10 shows removable barrier 120 having a tacky material 40 located on the perimeter of the removable barrier.

While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes, omissions and/or additions may be made and equivalents may be substituted for elements thereof without departing from the spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Moreover, unless specifically stated any use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. 

1. A self-adhesive face mask comprising a mask body sized to fit over a nose and mouth of a wearer and having a perimeter; and a tacky cured silicone material located on the perimeter of the mask body wherein the tacky cured silicone material removably adheres to human skin without residue.
 2. The self-adhesive face mask of claim 1, wherein the tacky cured silicone material is continuous around the perimeter of the mask body.
 3. The self-adhesive face mask of claim 1, wherein the tacky cured silicone material has a thickness of 0.1 to 4 mm.
 4. The self-adhesive face mask of claim 1, wherein the tacky cured silicone material has a width of 1 to 25 mm.
 5. A personal protection kit comprising a mask sized to cover a wearer's nose and mouth and having a perimeter size and shape; and a tacky cured silicone material having a size and shape to adhere to the mask perimeter size and to wearer's face.
 6. The personal protection kit of claim 5, wherein the tacky cured silicone material has a thickness of 0.1 to 4 mm.
 7. The personal protection kit of claim 5, wherein the tacky cured silicone material has a width of 1 to 25 mm.
 8. A protective face mask comprising a flexible mask body sized to fit over a nose and mouth of a wearer and having central opening and a removable barrier covering the central opening.
 9. The protective face mask of claim 8, wherein at least a portion of the flexible mask body is formed from a non-tacky cured silicone.
 10. The protective face mask of claim 8, wherein the central opening has a perimeter smaller than the perimeter of the removable barrier.
 11. The protective face mask of claim 8, wherein the central opening is surrounded by a tacky material.
 12. The protective face mask of claim 8, wherein the central opening is surrounded by a material different from the remainder of the flexible mask body.
 13. The protective face mask of claim 8, wherein the removable barrier is attached to the mask body by an interlocking attachment means.
 14. The protective face mask of claim 8, wherein the perimeter surrounding the central opening has a slot and the removable barrier is sized to fit the slot.
 15. The protective face mask of claim 8, wherein the flexible mask body has a side facing a wearer and a side opposite of the wearer and the removable barrier is located on the side facing the wearer.
 16. The protective face mask of claim 8, wherein the flexible mask body has a side facing a wearer and a side opposite of the wearer and the removable barrier is located on the side opposite of the wearer. 